Lexmark Color Jetprinter 1020 Service Manual
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Lexmark Color Jetprinter 1020 Service Manual

Lexmark Color Jetprinter 1020 Service Manual

Lexmark color jeprinter 1020 service manual
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Color Jetprinter™ 1020
4078-00X
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark Color Jetprinter 1020

  • Page 1 Color Jetprinter™ 1020 4078-00X • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    4078-00X Contents Preface ..........v Safety Information.
  • Page 4 4078-00X Repair Information ........4-1 Handling ESD-Sensitive Parts .

  • Page 5: Preventive Maintenance

    This manual is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
  • Page 6 4078-00X Sicherheitshinweise • Die Wartungsinformationen für dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen benützt werden. • Zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung existiert während des Auseinandernehmens und der Wartung des Geräts. Fachpersonal sollte im vollen Verständnis der Lage entsprechende Vorsichtsmaßnahmen ergreifen.
  • Page 7 4078-002 Pautas de Seguridad • La información sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario. • Existen mayores riesgos de descargas eléctricas y daños personales durante el desmontaje y la reparación de la máquina.
  • Page 8 4078-00X Chinese Safety Information Korean Safety Information viii...

  • Page 9: General Information

    The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. After you complete the repair, perform tests as needed to verify the repair. 1020 printer is a personal, near laser-quality “Start” on page 2-1. General Information 1-1...

  • Page 10: Abbreviations

    4078-00X Abbreviations Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer POST Power-On Self Test V ac Volts alternating current V dc Volts direct current Zero Insertion Force Unique Tools Required For Service Parallel Wrap Plug P/N 1319128...

  • Page 11: Diagnostic Information

    If an error indicator appears, go to the error indicator table and take the indicated action for that error. The printer also logs the last occurring error. If you think it may have an intermittent error, or the error indicator lights have been cleared, you can retrieve the error: 1.

  • Page 12: Error Indicator Table

    Light Flashes Blank Power-On Self Test (POST) Sequence When you turn the printer on it performs a POST. Turn your machine on and check for a correct POST operation by observing the following: 1. The lights come on. 2. The carrier moves.

  • Page 13: Post Symptom Table

    4078-00X POST Symptom Table Symptom Action No Power On Go to the light and no motors run Power light, but Replace the system board. no busy light Paper feed Go to the gears do not turn Carrier doesn’t Go to the move 2-6.

  • Page 14: Symptom Tables

    • No carrier movement • Slow carrier movement • Carrier stops • Carrier slams side frame Communications Problems Symptom Printer not communicating with host computer. Maintenance Station Problems Symptom Maintenance station: • Fails to cap the printhead • Fails to clean the printhead...
  • Page 15 4078-00X Paper Feed Problems Symptom • Fails to pick paper • Picks more than one sheet of paper • Picks paper but fails to feed • Paper jams • Paper fails to exit • Noisy paper feed Envelopes fail to feed Paper skews Power Problems Symptom...

  • Page 16: Service Checks

    Check the motor for binds, or loose motor pulley. Turn the printer off and disconnect CN4 from the system board. Turn the printer on and check for a pulse of (approximately) 10 V dc between CN4-1 and ground and CN4-4 and ground, on the system board, as the machine goes through P-O-S-T.

  • Page 17: Envelope Feed Service Check

    If the test fails, turn the printer off and disconnect CN5 from the system board. Turn the printer on and check for 5 V dc between CN5-1 and ground, at the system board. If the voltage is present, replace the home position sensor. If the voltage is not present, replace the system board.

  • Page 18: Maintenance Station Service Check

    4078-00X Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying. Maintenance Station Assembly Wiper Action As the carrier moves to the right over the maintenance station, a slot on the bottom of the...

  • Page 19: Paper Feed Service Check

    System Board Action Turn the printer off and disconnect CN6 from the system board. Turn the printer on and check for a pulse of 24 V dc between CN6-1 and ground and CN6-2 and ground on the system board, as the machine goes through P-O-S-T.
  • Page 20 4078-00X Paper Feed Motor Drive Train Assembly Auto Sheet Feeder Mid Frame Asm Access Cover End-of-Forms Flag and Spring 2-10 Action A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor •...

  • Page 21: Paper Path Service Check

    • Check the entire paper path for obstructions. • Be sure the correct type of paper is being used. • Be sure the printer is installed on a flat surface. Large and Small Feed Rollers Small Feed Roller Springs Auto Sheet...

  • Page 22: Parallel Port Service Check

    Carrier Home Sensor Parallel Cable System Board 2-12 Action Run a test page to be sure the printer can print. Run the “Parallel Port Test” on page fails, replace the system board. Action Disconnect CN7 from the system board and check the following voltages on the power supply cable: •...

  • Page 23: Print Quality Service Check

    4078-00X Print Quality Service Check FRU / Function Print Cartridge Color Print Cartridge Cross Contamination Printhead Carrier Assembly System Board Printhead Cable Rubber Backer Action Be sure the machine contains a good print cartridge. Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow, (when yellow and blue are mixed in the print cartridge).
  • Page 24 • Idler pulley parts for wear, damage, or looseness. Uneven vertical lines can be adjusted by performing the bidirectional alignment. The user is directed, through the Printer Control program, to perform the bidirectional printing alignment, when replacing a print cartridge. 2-8,...

  • Page 25: Print Quality Notice

    All FRU motors will be labeled NMB. After completing repairs to the printer, connect it to a PC and go to x :\Tools\4078 (where x is the letter of your CD-ROM drive) on your latest Service Information and Training CD-ROM and perform one of the following commands to download the file to your printer.

  • Page 26: Diagnostic Aids

    Use these diagnostic test procedures to verify a repair. The test procedures are entered by pressing and holding a button, or buttons, as you turn on the printer. To begin the test, hold the buttons until both the operator panel lights come on and then release the buttons after five seconds.

  • Page 27: Eof And Home Position Sensors Test

    This test allows the servicer to test the function of the End-of-Form and Home Position sensors. To run the test: 1. With the printer off and the End-of-Form Flag out of the sensor, press and hold the following buttons while turning the printer on: 2. Paper Feed 3.

  • Page 28: Initialize Error Log

    To run the test: 1. Place a sheet of paper in the sheet feeder far enough to push the End-of-Form flag out of the sensor. 2. With the printer off, hold down the Install Print Cartridge button while turning the printer on.

  • Page 29: Parallel Port Test

    If the test is not successful, the power on light remains off. To run the test: 1. With a parallel port wrap plug installed and the printer off, press and hold the following button while turning the printer on: 2. Paper Feed After five seconds, release the button to begin the test.

  • Page 30: Print Nvram Contents

    End-of-Form flag out of the sensor. 3. Load paper into the sheet feeder. 4. With the printer off, press and hold the Paper Feed button and turn the printer on. After five seconds, release the button to begin the test.

  • Page 31: Reset Nvram To Emea Defaults

    The page count and the error log do not change. Note: Factory defaults are initially set to USA. To run the test: 1. With the printer off, press and hold the following buttons while turning the printer on: •...

  • Page 32: Reset Nvram To Usa Defaults

    The page count and the error log do not change. Note: Factory defaults are initially set to USA. To run the test: 1. With the printer off, press and hold the Install Print Cartridge button while turning the printer on: 2.

  • Page 33: Test Page

    To enter the test: • Press and hold the Paper Feed printer on. Paper feeds from the sheet feeder and prints the test page. Pages continue to print until you turn off the power or unplug the printer. The test page prints the following lines.

  • Page 34: Repair Information

    4078-00X 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 35: Adjustments

    4078-00X Adjustments The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. Unplug the power cord before removing any parts.

  • Page 36: Access Cover Removal

    4078-00X Access Cover Removal 1. Open the access cover. 2. Push the mounting tabs towards the center of the machine. 3. Remove the access cover. Base Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4.

  • Page 37: Carrier Frame Assembly Removal

    4078-00X Carrier Frame Assembly Removal The carrier rail mounted by two screws on the carrier frame is included with the carrier frame (11A5436). The carrier rail, which is not available as a FRU, is mounted in the elongated slots at the factory. During adjustment, the rail is pushed to the rear as far as it will go, before the mounting screws are tightened.

  • Page 38: Carrier Transport Motor Removal

    4078-00X Carrier Transport Motor Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Disconnect the carrier transport motor connector from the system board. 4. Remove the belt from the carrier transport motor pulley. 5. Remove the two screws securing the carrier transport motor to the carrier frame and remove the motor.

  • Page 39: Front Cover Removal

    4078-00X Front Cover Removal 1. Turn the printer over to expose the base. Remove the two cover mounting screws from the front cover. When reassembling, do not overtighten these screws as they will break. Replacement screws can be found in parts packet 11A5453.

  • Page 40: Large Feed Roll Removal

    4078-00X Large Feed Roll Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4. Remove the base assembly. 5. Remove the system board. 6. Remove the printhead carrier assembly. 7. Remove the small feed roll assemblies. 8.

  • Page 41: Mid Frame Assembly Removal

    4078-00X Mid Frame Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4. Remove the system board. 5. Remove the small feed roll assemblies. 6. Remove the small feed roll bracket assembly. 7.

  • Page 42: Printhead Carrier Assembly Removal

    4078-00X Printhead Carrier Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4. Unlock the two printhead cable connectors and disconnect the printhead cable from the system board. 5. Unlatch the cable retainer from the carrier frame. 6.

  • Page 43: Rear Cover Removal

    4078-00X Rear Cover Removal 1. Remove the front cover. 2. Pry upwards on the two rear cover latches [A]. 3. Work the tabs of the rear cover free from the base assembly. 4. To reassemble, place the cover over the tabs in the base assembly and press towards the front of the machine until the cover latches.

  • Page 44: Sheet Feeder Removal

    4078-00X Sheet Feeder Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the two sheet feeder mounting screws from the rear of the carrier frame. 4. Unlatch the right sheet feeder latch from the front of the carrier frame.

  • Page 45: Small Feed Roll Bracket Assembly Removal

    4078-00X Small Feed Roll Bracket Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4. Remove the system board. 5. Remove the four small feed roller springs from the carrier frame. 6. Push down on each of the small feed roll assemblies to remove them from the small feed roll bracket.

  • Page 46: System Board Removal

    4078-00X System Board Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the sheet feeder. 4. Unlock the two printhead cable connectors and disconnect the printhead cables from the system board. 5. Disconnect the other cables from the system board. 6.

  • Page 47: Connector Locations

    4078-00X 5. Connector Locations System Board Connectors Connector Locations 5-1...
  • Page 48 4078-00X Connector LED1 LED2 Connector Names Printhead Cable 1 Printhead Cable 2 Carrier Transport Motor Home Position Sensor Paper Feed Motor Power Supply Parallel Port Power Switch Paper Feed Switch Install Print Cartridge Switch Busy Light Power on Light...

  • Page 49: Preventive Maintenance

    4078-00X 6. Preventive Maintenance This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease P/N 1329301 to lubricate the following: •...

  • Page 50: Parts Catalog

    4078-00X 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 51: Assembly 1: Covers

    4078-00X Assembly 1: Covers Parts Catalog 7-2...
  • Page 52 4078-00X Asm- Part Index Number 1 -1 11A5430 11A5431 11A5432 11A5433 11A5434 11A5435 11A5453 11A5454 Units Description Base Asm Felt Pad, Ink Absorption Cover, Front Asm Cover, Rear Asm Cover, Access Asm Garage Asm Front Cover Mounting Screws (PP) Replaceable Package B/M - Includes: (Carton, Cushion Set, Sealing Tape)

  • Page 53: Assembly 2: Paper Feed / Carrier Transport / Maintenance

    4078-00X Assembly 2: Paper Feed / Carrier Transport / Maintenance Parts Catalog 7-4...
  • Page 54 4078-00X Asm- Part Index Number 2 -1 11A5436 11A5438 11A5450 11A5453 11A5453 11A5441 11A5442 11A5443 11A5444 11A5453 11A5453 11A5449 11A5453 11A5440 11A5439 11A5452 11A5453 11A5453 11A5453 1367389 Units Description Frame, Carrier Sensor, Carrier Home Motor, Carrier Transport Asm “Print Quality Notice” on page 2-15.

  • Page 55: Assembly 3: Electronics

    4078-00X Assembly 3: Electronics Parts Catalog 7-6...
  • Page 56 4078-00X Asm- Part Index Number 3 -1 11A5455 11A5447 11A5446 11A5453 Units Description System Board with ROM “Print Quality Notice” on page Power Supply: 110V Power Supply: 220V Screws, System Board (PP) 2-15.

  • Page 57: Assembly 3: Electronics (Continued)

    4078-00X Assembly 3: Electronics (Continued) Parts Catalog 7-8...
  • Page 58 4078-00X Asm- Part Index Number 3 -4 1339526 1342536 1339520 1339520 1342514 1342526 1342536 1339526 1342534 1342514 1342514 1339525 1342514 1339519 1342514 1339520 1339520 1339520 1342514 1342514 1339521 1339524 70G0496 1342514 1339520 1342514 1339520 1342514 1342536 1342514 1339520 1339517 1339523 1339520 1339520 1339522...

  • Page 59: Assembly 4: Carrier

    4078-00X Assembly 4: Carrier Parts Catalog 7-10...
  • Page 60 4078-00X Asm- Part Index Number 4 -1 11A5448 11A5437 11A5436 11A5453 11A5453 7-11 Units Description Carrier Assembly Rod, Carrier Guide Frame, Carrier Screw, Carrier Guide Rod (PP) Spring, Carrier Guide Rod (PP)

  • Page 61: Assembly 5: Sheet Feeder

    4078-00X Assembly 5: Sheet Feeder Parts Catalog 7-12...

  • Page 62: Index

    4078-00X Asm- Part Index Number 5 -1 11A5436 11A5453 11A5451 11A5433 70G2759 7-13 Units Description Frame, Carrier Screws, Sheet Feeder Mounting (PP) Sheet Feeder Asm Cover, Rear Asm Card Feeder Kit, Japan Hagaki...
  • Page 63 4078-00X Index Abbreviations Adjustments Assemblies 1 Covers 2 Carrier Transport 2 Maintenance Station 2 Paper Feed 3 Electronics 7-10 4 Carrier 7-12 5 Sheet Feeder Connector Locations Connectors System Board Diagnostic Aids Diagnostic Information Error Indicator Table ESD-Sensitive Parts General Information Lubrication Specifications Maintenance Approach Parts Catalog...
  • Page 64 4078-00X Parallel Port Print NVRAM Contents Reset NVRAM Defaults EMEA Test Page Tools...

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